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Part No. 08164SL (Rev. A)
ServiceManual
R
Workman MDE
Preface
Thepurposeofthispublicationistoprovidetheservice
technician with information for troubleshooting, testing
and repair of major systems and components on the
Workman MDE.
Thissafetysymbol meansDANGER, WARNING
REFERTOTHEOPERATOR’SMANUALFOROPER-
or CAUTION, PERSONAL SAFETY INSTRUC-
ATING, MAINTENANCE AND ADJUSTMENT IN- TION.Whenyouseethissymbol,carefullyread
the instructions that follow. Failureto obeythe
STRUCTIONS. For reference, insert
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TableOfContents Chapter1 -- Safety Safety Instructions.......................... 1 -- 2 Jacking and Other Instructions ............... 1 -- 4 Safety and Instruction Decals ................ 1 -- 5 Chapter2 -- ProductRecordsand Maintenance Product Records ........................... 2 -- 1 Maintenance............................... 2 -- 1 Equivalents and Conversions ................ 2 -- 2 Torque Specifications ....................... 2 -- 3 Chapter3 -- Electrical System General Information ......
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Chapter1 Safety TableofContents SAFETYINSTRUCTIONS ...................... 2 Before Operating............................ 2 While Operating............................. 2 Maintenance and Service .................... 3 JACKING AND OTHER INSTRUCTIONS......... 4 Jacking Vehicle ............................. 4 Towing Vehicle.............................. 4 Transporting Vehicle ......................... 4 SAFETYAND INSTRUCTION DECALS .......... 5 Workman MDE Page1 -- 1 Safety Safety
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SafetyInstructions TheWorkmanMDEisdesignedandtestedtooffersafe service when operated and maintained properly. Al- WARNING thoughhazardcontrolandaccidentpreventionarepar- tially dependent upon the design and configuration of themachine,thesefactorsarealsodependentuponthe To reduce the potential for injury or death, awareness,concernandpropertrainingoftheperson- complywiththefollowingsafetyinstructions. nel involved in the operation, transport, maintenance and storage of the machine. Improper use
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MaintenanceandService 1. Before servicing or making adjustments to the ve- 10.Never use an open flame to check level or leakage hicle, stop vehicle, turn on/off switch to OFF, engage ofbattery electrolyte. parking brake and remove key from the on/offswitch. 11.Whenconnectingthebatterychargertothevehicle, 2. Makesuremachineisinsafeoperatingconditionby connectthechargercordtothevehiclechargerrecep- keeping all nuts,bolts and screws tight. tacle before plugging the charger power cord into an outlet
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JackingandOtherInstructions JackingVehicle DANGER POTENTIALHAZARD • Avehiclethatisnotproperlysupported maybecomeunstable. WHATCANHAPPEN • Thevehiclemaymoveorfall.Personal injuryordamagetothemachinemayresult. HOWTOAVOIDTHEHAZARD 1 • Makesurevehicleisparkedonasolidlevel 2 surface,suchasaconcretefloor. • Makesureon/offswitchisOFFandkeyis Figure 1 removedfromtheswitchbeforegettingoff 1. Frontframe 2. Towingtongue thevehicle. • Beforeraisingthevehicle,removeany attachmentsthatmayinterferewiththesafe
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SafetyandInstructionDecals Thereareseveralsafetyandinstructiondecalsattached toyourWorkmanvehicle.Ifanydecalbecomesillegible ordamaged,installanewdecal.Partnumbersarelisted in the Parts Catalog. Order replacement decals from your Authorized Toro Distributor. Workman MDE Page1 -- 5 Safety Safety
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Chapter2 ProductRecordsandMaintenance TableofContents PRODUCT RECORDS......................... 1 MAINTENANCE............................... 1 EQUIVALENTSAND CONVERSIONS ........... 2 Decimal and Millimeter Equivalents ............ 2 U.S.to Metric Conversions ................... 2 TORQUESPECIFICATIONS.................... 3 Fastener Identification ....................... 3 Standard Torque for Dry,Zinc Plated and Steel Fasteners (Inch Series) ............... 4 Standard Torque for Dry,Zinc Plated an
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EquivalentsandConversions 0.09375 ProductRecordsandMaintenance Page2 -- 2 Workman MDE
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TorqueSpecifications Recommendedfastenertorquevaluesarelistedinthe Asnotedinthefollowingtables,torquevaluesshouldbe followingtables.Forcriticalapplications,asdetermined reduced by 25% for lubricated fasteners to achieve byToro,eithertherecommendedtorqueoratorquethat thesimilarstressasadryfastener.Torquevaluesmay isuniquetotheapplicationisclearlyidentifiedandspe- alsohavetobereducedwhenthefasteneristhreaded cified in this Service Manual. into aluminum or brass. The specific torque value shouldbed
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8withThin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 5 or Stronger Nuts) in--lb in--lb N--cm in--lb N--cm in--lb N--cm # 6 -- 32 UNC 15 + 2 169 + 23 23
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StandardTorqueforDry,ZincPlatedandSteelFasteners(MetricSeries) Class8.8Bolts,ScrewsandStudswith Class10.9Bolts,ScrewsandStudswith T Thread hreadS Size ize R Regular egularH Height eightN Nuts uts R Regular egularH Height eightN Nuts uts (Class8orStrongerNuts) (Class10orStrongerNuts) M5 X 0.8 57 +6in--lb 644 + 68 N--cm 78 +8in--lb 881 +90N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 +14 in--lb 1503 + 158 N--cm M8 X1.25 19 +2ft--lb 26 +3N--m 28 +3ft--lb 38 +4N--m M10 X1.5 38 +4ft--lb 52 +5N--
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OtherTorqueSpecifications SAEGrade8SteelSetScrews WheelBoltsandLugNuts RecommendedTorque ThreadSize RecommendedTorque** Thread ThreadS Size ize SquareHead HexSocket 7/16 -- 20 UNF 65 + 10 ft--lb 88 +14N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 1/2 -- 20 UNF 80 + 10 ft--lb 108 + 14 N--m 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb Grade 5 3/8 -- 16 UNC 35 + 10 ft--lb 18 +3ft--lb M12 X1.25 80 + 10 ft--lb 108 + 14 N--m Class 8.8 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb M12 X1.5
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Chapter 3 Electrical System Table of Contents GENERAL INFORMATION ..................... 2 SERVICEAND REPAIRS ..................... 28 Operator’s Manual .......................... 2 Battery Service ............................ 28 Opening Battery Circuit ...................... 2 Battery Specifications ..................... 28 ELECTRICAL DIAGRAMS...................... 3 Battery Removal.......................... 29 VEHICLEOPERATION ........................ 4 Battery Installation ....................
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GeneralInformation TheWorkmanMDEusesa48voltDCelectricalsystem LEDonthecontrollerandthevehiclestatuslightonthe thatisanisolatedcircuit.Thevehicleframeisnotused dashpanelwillflashafaultcodetoassistinidentifying for any ground connections. the problem. Thevehiclecontrollermonitorsoperatorandvehiclein- Afterperforminganyrepaironelectricalcomponentson putstodeterminevoltagetothetractionmotor.Ifaprob- thevehicle,makesurethatwiringisroutedandsecured lemexiststhatwillpreventnormalvehicleoperation,an soa
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ElectricalDiagrams Theelectricalschematic,circuitdrawingsandwirehar- ness drawings for the Workman MDE are located in Chapter 6 -- Electrical Diagrams. Workman MDE ElectricalSystem Page3 -- 3 Electrical System
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VehicleOperation TheWorkmanMDEelectricalsystemusesa48voltbat- Thevehiclecontrollerisasealedelectroniclogicdevice terypack,anelectrictractionmotor,avehiclecontroller that uses inputs from several vehicle components to andnumerousotherelectricalcomponentstoallowve- controlmotorspeedanddirection.Theseinputsinclude hicle operation. several switches (on/off, forward/reverse, accelerator, supervisor, charger), a motor temperature sensor, an Eight,6volt,deepcyclebatteriesthatareconnectedin acceleratorp
